perry



R. P. PERRY.

FELT AND PROCESS OF MAKING THE SAME.

APPLICATION FILED APR. 12. 1911. 1,305,404.

RENEWED NOV. 20.1918.

Patented June 3, 1919.

//V ITVVENTO/ 7% W WW 4 TTORNE Y UNITED STATES PATENT OFFICE.

RAY P. PERRY, OF

UPPER MONTCLAIR, NEW JERSEY, ASSIGNOR TO THE BARRETT COMPANY, A CORPORATION OF NEW JERSEY.

FELT AND PROCESS or MAK1NG THE SAME.

Specification of Letters Patent.

Patented June 3, 1919.

Application filed April 12, 1917, Serial No. 161,670. Renewed November 20, 1918. Serial No. 263,442;

To all whom it may concern:

Be it known that I, RAY P. PERRY, a citizen of the United States, residing at Upper Montclair, in the county of Essex and State of New Jersey, have invented certain new the manufacture of such roofing materials,

to use so-called dry felt or unsaturated felt or paper which is ordinarily waterproofed by saturating with bltuminous material, and often the saturated felt is coated with a superficial layer, on one or both faces, of asphalt or other waterproofing and Weather-resisting material. The dry felt or dry roofing paper is generally manufactured from old rags or other fibrous materials which are beaten in the presence of a large amount of water into a pulp, either alone or in combination with beaten old papers, and the pulp is formed into sheets in the manner common in the manufacture of papers and felts.

The object of my invention is to manufacture a substitute for the so-called dry felts previously used in the manufacture of roofing materials such as the rubber roofings previously referred to, which shall be cheaper and more convenient to manufacture, and shall already contain a predetermined amount of comminuted waterproofing material in solid form. The product of my invention may be open and porous sufficiently to permit saturation, and has other desirable properties subsequently to be described.

My process, briefly stated, comprises adding to the usual watery pulp of beaten rags or paper, or a mixture of the two, or other fibrous or paper making material in the form of a watery pulp, a predetermined amount of subdivided or comminuted waterproofing material in solid form, such as comminuted hard or soft coal tar pitch, asphalt, or other solid bituminous material, stearin pitch, cotton-seed pitch, petroleum wax,

resins, etc., all of which I intend shallbe comprehended by the term bituminous inaterial. These materials are readily. fusible, and of a waterproofing and weather-resisting nature. By the term comminuted, as used in the specification and claims, I mean to designate bituminous material in the form of small particles orpieces of any desired shape or form. Such particles or fragments may be in the form of a coarse or fine powder, irregular flakes or fragments, or in the form of shot. I prefer, however, to use such material in the form of hairs or filamentsv such as are described in my copending application filed March 27, 1917, bearing Serial Number 157,7 52, and entitled Bituminous materials in filamentary formand processes and apparatus for making the same. Such filaments may be of varying length and often are broken into fragments, and I, therefore,

intend that the term filament as used in the specification and claims shall include long or short filaments or fragments of the same. Preferably the addition of the predethe watery pulpof paper stock is worked in the beater long enough to bring about a substantially uniform mixture of the materials present in the beater. The mixture is later fed at a predetermined rate into the paperforming vat or tank, where, by means of the usual woolen blanket or wet felt and the usual couche roll passing over the usual perforated brass or other cylinder, the mixture of pulp and comminuted bituminous material is formed into a sheet or layer which may then be dried in the manner common in the manufacture of papers and felts.

The paper stock may consist entirely of rags, or entirely of paper, or of a mixture of rags and paper in any desired proportion, or other animal, vegetable or'mineral fibrous material, in any desiredproportions alone or in combination with various fillers or substitutes. I have found that as a result of the addition of the solid comminuted bituminous material I may use a larger proportion of paper or other so-called hard stock and a smaller proportion of rags or soft stock than has hitherto been deemed feasible, and still leave the resulting sheet open and porous enough to absorb the desired amount of saturating or waterproofing material during the subsequent saturating step.

Referring to the drawingwherein I have illustrated diagrammatical a device for making the product and practising the process of my invention,

1 shows diagrammaticai for disintegrating rags, papers or paper stock to beiised in the manuf my lat. The stock 9; is llSl1l l5 t Ll be tween the bed plate 2 and the rotary cutting member 3, the operation resulting in a circulation of the watery pulp in the beater. Generally the beating operation requires from one-half to two hours to complete, dependent upon the character of stock used to make the felt. A short while before the disintegration of the paper stock is complete, generally about 5 to 20 minutes before the fibrous stock is completely disintegrated, i add to the pulp in the beater a predetermined quantity of comminuted bituminous material in solid form. The heater is he in operation after such addition until t a pulp and bituminous material are sue stantially uniformly intermixed.

T/ hen the mixture is complete, it is dropped into the beater chest or sto" tank, and is later transferred to the r and screenswhich remove foreign mate and lumps of fabrous material which have not been sufficiently disintegrated or pulp-ed, and passes to the cylinder vat 6 where the sheet of felt or paper is formed.

Within the cylinder vat 6 rotates the screen cylinder mold 7 of the type usual in the paper-making industry. difference in hydrostatic level between the interior and the exterior of the cylinder produces a suction and draws the water through the perforations of the screen on the periphery of the cylinder mold, causing a layer 11 of pulp to be formed. ihis layer 11, consisting of a substantially uniform mixture of comminuted bituminous material in solid form and watery pulpy paper-forming stock, is picked off by the s-o-called wet felt or woolen blanket endless belt 12, which passes under the couche roll 8 and by it is pressed against the layer 11 which then adheres to the wet felt 12 as a sheet of felt or paper 13 traveling as indicated by the arrow. In its travel it may pass over-one or more suction boxes, as shown at 14, and below a press roll 15, which remove some of the water from the sheet 13 and mats it together sufiiciently so that now it can be led to the series of revolving drier rolls 10 which are steamheated, and serve to evaporate most of the water in the sheet 13. A suflicien't number of driers are used so that by the time the sheet 13 has passed over all of them it becomes a substantially dry sheet of paper or felt, and is wound into rolls, or otherwise disposed of for use or for shipment.

lf desired, the drying action may be continued so long and at such a temperature that a. slight softening or fusing of the comminuted bituminous material in solid form talres place, whereby a sort of cementing action is brought about causing the sheet to be st e thened and rendered more coherent.

hiie an form of comminuted or subdiied bitum one material may be employed,

et tort-h, I prefer to use such mate ial in the form of hairs or filaments. The advantage of such a form of comminuted bituminous material is that less of the bituminous material is wasted by being washed aw y with he water in the screening of paper-form operation, and a more thorough interm sting and. interweaving e the fibro and bituminous material is fr/16m" *ial, the

While stock 11h} be a mixture of rags a t dal proportions by w o-rtions may be varied nave described the comm .ed solid bituminous material as acded to the paper stock while in heaters, and while this will ordinarily be preferred practice, it may be desirable, in some cases, to introduce the bituminous material to the heaters in comparatively large masses or pieces. These relatively large masses are subdivided or oomminu'ted by the action of the heater, and the desired mixture is thus obtained. It is immaterial for the purposes of my invention just how the bituminous material is introduced, so long as it is finally obtained in the comminuted or subdivided form mixed with and distributed throughout the watery pulpy stock which 1s used to form the sheet of felt'or paper, or is distributed in such form on or through such sheet.

I have found that by the use of my invention I can, if desired, produce a useful construction material without using the step of saturating the sheet as was common in the former practice.

Wherever I use the expression unsaturated building felt or construction ma-' terial it is to be understood that I intend to include such articles as in the unsaturated form are used for roofing and sheathing or are later saturated or impregnated with waterproofing material and used in the manufacture of roofings, sheathing, and flooring. The articles are flexible and porous, the de- "gree of flexibility and porosity varying somewhat with the nature and relative proportions of the fibrous and waterproofing materials.

What I claim is:

1. As an article of manufacture, abody comprising fusible waterproofing material in filamentary form and disintegrated paper stock material.

2. As an article of manufacture, a body comprising waterproofing material in solid filamentary form and disintegrated paper stock material.

3. As an article of manufacture, a sheet of flexible and porous unsaturated building felt consisting of a felted mass of comminuted bituminous material in the form of elongated particles and other material.

4. As an article of manufacture, a sheet of flexible and porous unsaturated building the felt stronger and better knitted together.

6. As an article of manufacture, a construction material comprising a felted mass of bituminous filaments and fibrous mate rial, impregnated with bituminous material.

7. As an article of manufacture, a construction material comprising a felted mass of bituminous filaments and fibrous material.

8. As an article of manufacture, a sheet of flexible and porous building felt comprising a felted mass of bituminous filaments and fibrous material, impregnated with a water roofing material.

9. s an article of manufacture, a sheet .of flexible and porous unsaturated building felt consisting of a felted. mass of comminuted pitch in the form of elongated particles and other material.

11. As an article of manufacture, a construction material comprising a felted mass of pitch filaments'and fibrous material.

12. As an article of manufacture, a sheet of flexible and porous unsaturated building felt comprising paper stock fibers in felted form having solid pitch filaments distributed therethrough. 13. The process of making felt which comprises adding a predetermined quantity of bituminous filaments to a pulp of fibrous material, forming the mixture into a layer, drying the layer to form a felt, slightly softening the bituminous filaments to cause the same to adhere more closely to the other material present in the felt, and impregnating the felt with bituminous material.

14. The process of making felt which comprises adding a predetermined quantity of bituminous filaments to a pulp of fibrous material, mixing the pulp and bituminous filaments intimately together, forming the mixture into a layer, drying the layer to form a felt, slightly softening the bituminous filaments to cause the same to adhere more closely to the other material present in the felt and impregnating the felt with bituminous material.

15. The process of making felt which comprises forming a watery pulp of fibrous material and a predetermined quantity of bituminous filaments, mixing the pulp. and bituminous filaments intimately, together, forming the mixture into a layer, forming a felt by drying the layer, softening the bituminous filaments slightly to cause the same to adhere more closely to the other material-present in the felt, impregnating the felt with bituminous material, and coating the impregnated felt with a Waterproofing material.

16. The process of' making felt which comprises adding a predetermined quantity of fusible material in the form of filaments to a pulp of paper-making material, forming the mixture into a layer, and forming the layer into a sheet of paper.

17. The process of making felt which comprises adding a predetermined quantity of filaments of fusible material to a watery pulp of fibrous material, mixing the filaments of fusiblematerial and fibrous material intimately together, forming the miX ture into a layer, drying the layer to form a felt, and slightly softening the filaments of fusible material to cause the same to adhere 5 more closely to the fibrous material present in the felt. 18. The process of making felt which comprises adding a predetermined quantity of fusible material in the form of filaments to a pulp of paper-making material, form- 10 ing the mixture into a layer, forming the. layer inte a sheet of pa er, and saturating the sheet with moltenbltuminous material. In testimony whereof I afiix my signature.

I RAY P. PERRY. 

